Mosaic construction



March 7, 1967 L. G. SIMJIAN 3,308,226

MOSAIC CONSTRUCTION Filed Nov. 8, 1963 2 Sheets-Sheet l CONTROL |7 1 l8 --MOT|ON MOTION scANw l rge I REPRODUCING MEA 4/ MEANS INVENTOR. LUTHER G. SIMJIAN EN A- v AGENT.

United States Patent Ofifice 3,388,226 Patented Mar. 7, 1967 3,308,226 MOSAIC CGNSTRUCTION Luther G. Simjian, Laurel Lane, Greenwich, Conn. 06830 Filed Nov. 8, 1963, Ser. No. 322,378 6 Claims. (Cl. 264-245) This invention concerns mosaic constructions and has particular reference to the construction of a mosaic which is the solid reproduction of another object as disclosed in my copending applications for US. Letters Patent Serial No. 189,141, filed April 20, 1962, entitled: Apparatus for Providing Solid Reproductions, now US. Patent No. 3,135,828, dated June 2, 1964 and Serial No. 315,027, filed October 9, 1963, entitled: Method and Apparatus for Providing Solid Reproductions.

In the applications noted heretofore, I have disclosed the production of mosaics which result from the scanning of a pictorial representation, such as a painting, a photograph, a sign and the like. Briefly, an object of the type indicated is mounted in front of a scanning means which scans the different areas of the object and provides color responsive output signals. A reproducing means which includes picture element storage and dispensing means receives the color responsive signals and dispenses solid preshaped colored picture elements onto a base sheet in accordance with the signals from the scanning means. Motion control means provide motion to the scanning means and also cause the reproducing means to assume at any instant a position which corresponds to the position of the scanning means relative to the object. In this way the reproducing means generates a solid reproduction of a photograph or painting.

The present invention is related particularly to the method of further processing the deposited solid picture elements for providing a mosaic construction which is endowed with permanency and a pleasing appearance. Also the solid reproduction as described hereinafter, when processed in accordance with the teachings of this disclosure, will be a more accurate and faithful reproduction of the original copy.

One of the objects of this invention is, therefore, the provision of a method for arrangement and processing solid reproductions of the type disclosed in the patent applications noted heretofore.

Another object of this invention is the provision of means for providing rigidity to mosaic type reproductions.

Another object of this invention is the provision of means for improving the appearances and faithfulness of solid reproductions which are constructed from loose solid picture elements that have been deposited in a juxtaposed position onto a base sheet.

A further object of this invention is the provision of means for holding, retaining, and interlocking solid preshaped picture elements which have been deposited in a flat array by a controlled reproducing means.

Still further and other objects of this invention will be apparent by reference to the following description when taken in conjunction with the accompanying drawings, in which: 1

FIGURE 1 is a schematic block diagram of the apparatus for producing solid reproductions of an object;

FIGURE 2 is a plan view of a typical pictorial representation which is to be reproduced;

FIGURE 3 is a plan view of the solid reproduction of the representation of FIGURE 2, showing the .eproduction to comprise individually deposited solid icture elements;

FIGURE 4 is an elevational view for explaining one typical method of bonding the solid picture elements which comprise the mosaic to one another;

FIGURE 5 is a cross-sectional elevational view of an alternative method of retaining the individual picture elements in the mosaic;

FIGURE 6 shows still another method of providing rigidity to the array of juxtaposed solid picture elements;

FIGURE 7 illustrates schematically a further method of improving the appearance of the mosaic after the picture elements have been deposited;

FIGURE 8 indicates schematically the use of a grid for spacing and retaining solid picture elements which have been deposited to form a mosaic; and

FIGURE 9 is a variation of FIGURE 8, indicating the use of picture elements of another configuration.

Referring now to the figures and FIGURE 1 in particular, a scanning means 11 scans a pictorial representation 12 disposed in front of the scanning means and provides via a control means 13, color responsive signals to a producing means 14 which includes picture element storage and dispensing means. The dispensing means releases solid picture elements 15 which are deposited by the reproducing means onto a base sheet 16. The color of the elements released by the dispensing means is responsive to the signal from the scanning means. The control means 13, via motion control means 17 and 18, positions respectively the scanning means 11 and the reproducing means 14 to areas which coincide with the respective positions on the object 12 and the reproduction.

FIGURE 2 is a plan view of a typical picture 12 which is scanned by the scanning means while FIGURE 3 shows the same picture reproduced in mosaic form, partially completed. The solid, preshaped picture elements, or tiles, forming the solid reproduction are disposed in juxtaposed position on the base sheet 16. The reproduction may either be an enlarged or a reduced size presentation.

FIGURE 4 shows a schematically the array of juxtaposed picture elements just after their release from the reproducing means 14 and placement onto a base sheet or base plate 24. It will be apparent that some method or means must be employed to impart rigidity and permanency to the array of elements, as for instance, by bonding the individual, loose elements to one another and/or to the base.

Although, in a general way, several ways of accomplishing this task have been indicated in my copending applications for US. Letters Patent, Serial No. 189,141 supra, the following description provides some specific examples of not only bonding the picture elements into a permanent structure, but also to enhance the appearance of the finished mosaic.

In FIGURE 4 the elements 22 are placed upon a base plate, for instance a steel plate 24. The interstices between the elements are then filled with a thermoplastic resin 26 which originally is in powder form, as indicated in an enlarged scale in FIGURE 4B. Next, the array of elements still disposed on the steel plate is heated, causing the resin to flow and to cure, thereby holding the elements to one another and permitting the base plate 24 to be removed. The mosaic now is a self-supporting structure. The picture elements may either be of a porcelain substance or of a plastic material which has a higher softening temperature than the resin which fills the interstices.

In FIGURE 5 picture elements 32 of spherical shape are deposited upon a base sheet 34 which is provided along its surface with spherical recesses 36 to hold and align the individual elements 3-2. It will be apparent that the spacing between the recesses and the incremental motion of the reproducing means is adjusted so as to cause a dispensed element to be disposed in the proper recess. The base sheet 34 is made of thermoplastic material and hence, upon heating the base sheet, the elements are bonded to the sheet and thereby to one another. If desired, a

duplicate of the base sheet can be used as a cover sheet 38 and placed upon the completed array of elements. The elements are then enclosed and held between a fitted bottom and top sheet as shown in FIGURE 5B. Upon heating, the top and bottom sheet are caused to bond to the elements and to one another. The mosaic is now a self-supporting structure with the elements positively held and locked in place. It will be apparent that the enclosing sheets should be of clear transparent material, but in some instances, when desired, a slight line may enhance the appearance of the reproduction. When the elements are made of material which slightly softens during the heating process, e.g. thermoplastic material, the elements become even more firmly embedded within the top and bottom sheet so that the final reproduction is a matrix with a prearranged array of solid picture elements firmly embedded therein.

FIGURE 6 illustrates an alternative construction and shows a grid plate 4-2 which is provided with a multitude of circular apertures 44. Spherical picture elements 46 forming the mosaic pattern are inserted into the apertures of the grid plate, and finally a bond is achieved between the grid plate and the elements. Either the grid plate, the elements, or both, may be made of thermoplastic material to achieve the desired bond.

In FIGURE 7 the solid elements 52 dispensed from the reproducing means are deposited in an array of juxtaposed elements upon a base plate 54, such a steel plate. The elements are made of a material which deforms and flows upon the application of a compressive force. When a top plate 56 is placed upon the array of elements 52 and sufiicient pressure is applied as indicated in FIGURE 7B, the elements are stressed beyond their yield point and are caused to flow laterally into one another so that their side faces merge into one another as indicated schematically in FIGURE 7C. This procedure considerably enhances the appearance of the finished mosaic since substantially all interstices are eliminated and the finished reproduction appears to be a continuous surface. By this method the sharp delineation between adjacent picture elements disappears and a merging of colors takes place.

The variation depicted in FIGURE 8 shows a grid plate 62, the openings of which are filled with elements 64, for instance plastic spherical members. The grid plate, in a typical example, is aluminum and is disposed medially with respect to the height of the elements. When pressure is applied upon the projecting ends of the elements 64, they are deformed so as to flow around the grid structure, thereby causing the grid structure to become embedded in the mosaic. The grid provides the structural strength, thus causing the mosaic to be a self-supporting structure. When the pressure is of sufficient magnitude, the elements can be made to flow onto one another, similar to the design in FIGURE 7, thereby rendering, what appears to be, a continuous solid reproduction. This reproduction may be viewed also from either side if the original elements are uniform in color composition.

FIGURE 9 shows substantially the same construction as that in FIGURE 8 except that rectangular elements 72 are placed into the apertures of a grid plate 74. When pressure is applied to the elements which is of sufficient magnitude to permanently deform the elements, the grid plate becomes embedded in the solid reproduction. In the examples per FIGURES 6, 8 and 9, the grid plate acts originally as a spacing guide and retainer for the picture elements and finally, provides the structural strength for the mosaic-type reproduction.

It will be apparent that the above methods and processes provide solid reproductions which are eminently suited for decorative purposes.

When a fine color graduation is desired, the dispensing means, instead of containing preshaped solid picture elements, can be constructed to contain colored powder, the color of which corresponds to the three primary colors plus white and black. Mixing means cause mixing of the respective powder quantities to provide the desired color. The mixed quantity is then compacted into a solid element prior to release from the dispensing means. If the powder is thermoplastic material, the compacted element cures during the bonding process described heretofore. In this manner, a most accurate reproduction of paintings and color photographs is achieved as all tones of color can faithfully be reproduced. Instead of curing the compacted element during bonding, heating means, for instance a radio frequency heating coil, can be provided to cure each element immediately before the deposition thereof on the base sheet.

While there have been described and illustrated certain embodiments of the present invention, it will be apparent to those skilled in the art that various further changes and modifications may be made therein without deviating from the scope of the invention which shall be limited only by the scope of the appended claims.

What is claimed is:

1. A method of reproducing a colored painting, photograph or sign comprising:

(a) automatically depositing suita'ble colored resinous deformable solid picture elements in the openings of a grid plate so that said grid plate is disposed medially with respect to the height of said elements;

( b) applying heat and pressure to cause lateral deformation of said elements to embed said grid plate,

(c) so as to form a colored mosaic reproduction.

2. A method as set forth in claim 1 wherein said elements are spheres.

3. A method as set forth in claim 1 wherein said elements are cubes.

4. A method as set forth in claim 1 wherein said grid plate is made of resin.

5. A method as set forth in claim 1 wherein said grid plate is made of metal.

6. A method as set forth in claim 5 wherein said grid plate is made of aluminum.

References Cited by the Examiner UNITED STATES PATENTS 2,499,134 2/1950 De Bruyne 156-283 2,568,126 9/1951 Keeley 156-298 2,576,864 11/1951 Valenti 156-297 X 2,902,726 9/ 1959 Berreski. 3,028,283 4/ 1962 Lundgren et al 15663 X FOREIGN PATENTS 247,282 2/ 1926 Great Britain.

ALEXANDER WYMAN, Primary Examiner.

JACOB STEINBERG, Examiner. 

1. A METHOD OF REPRODUCING A COLORED PAINTING, PHOTOGRAPH OR SIGN COMPRISING: (A) AUTOMATICALLY DEPOSITING SUITABLE COLORED RESINOUS DEFORMABLE SOLID PICTURE ELEMENTS IN THE OPENINGS OF A GRID PLATE SO THAT SAID GRID PLATE IS DISPOSED MEDIALLY WITH RESPECT TO THE HEIGHT OF SAID ELEMENTS; (B) APPLYING HEAT AND APRESSURE TO CAUSE LATERAL DEFORMATION OF SAID ELEMENTS TO EMBED SAID GRID PLATE, (C) SO AS TO FORM A COLORED MOSAIC REPRODUCTION. 